Feed Manufacturing with Feed Manufacturing with DDGSDDGS

Kim Koch, Ph.D.Kim Koch, Ph.D.Northern Crops InstituteNorthern Crops Institute

United States Ethanol OutlookUnited States Ethanol Outlook

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2001 2003 2006 2012

Corn (bil. Bu.)Ethanol (bil. Gal.)DDGS (mmt)

Source: H. D. Tilstra

Values are Underestimated

DryDry--Milling Average Yield Per Bushel of CornMilling Average Yield Per Bushel of Corn

Ethanol 2.7 gal. (10.2 liters); COEthanol 2.7 gal. (10.2 liters); CO22 18 lbs. (8.2 kg); DDGS 18 lbs. (8.2 kg) 18 lbs. (8.2 kg); DDGS 18 lbs. (8.2 kg) ••Every gallon of ethanol produced = 6.67 lbs. (3.02 kg) of DDGSEvery gallon of ethanol produced = 6.67 lbs. (3.02 kg) of DDGS••Current estimate is ?? million gallons = ??? Current estimate is ?? million gallons = ??? mmtmmt of DDGSof DDGS

What is DDGS?DDGS is a by-product of fuel ethanol production• Typically from a dry-grind facility

Whole kernel processingNutrient content of DDGS depends on the grain source• Corn DDGS – Midwest US• Wheat DDGS – Canada• Sorghum (milo) DDGS – Great Plains US• Barley DDGS – Canada/US

Other by-products• DDGS from beverage alcohol – whiskey distilleries (dry grind)• Corn gluten feed – high fructose corn syrup, starch (wet mill)• Corn gluten meal – high fructose corn syrup, starch (wet mill)• Brewer’s grains (wet/dry) – beer production (dry grind)

Nutrient profile of by-products from dry-mill, wet-mill, and beverage alcohol production is different

from Shurson, 2006

Dry Milling ProcessDry Milling Process

Corn GroundCooked Fermentation

Distiller’s Grains(DDG) DistilledSeparated

Thin StillageCondensed Solubles

(CDS)

EthanolDDG + S(DDGS)

CO2Alpha amylase

Yeast & gluco-amylase

Liqui-faction

Source: H. D. Tilstra

Dry-Grind Ethanol By-Products used by Livestock (Poultry)

Wet distiller’s grains• Fed primarily to beef, some dairy – Total Mixed Rations (TMRs)

Dry distiller’s grains (DDG)• Fed to beef and dairy – concentrates

Wet distiller’s grains with solubles (WDGS)• Fed to beef and dairy - TMRs

Dried distiller’s grains with solubles (DDGS)• Fed to dairy, swine, poultry, some beef – concentrates, complete

feedsModified wet cake (blend of wet and dry distiller’s grains)• Fed primarily to beef, some dairy - TMRs

Condensed distiller’s solubles (CDS)• Fed to beef and dairy – TMRs• Ontario, Canada – swine liquid feeding system

from Shurson, 2006

DDGS Physical Characteristics

Knott, Shurson and Goihl• Bulk Density

Average = 45.9 kg/hlRange 39.6 – 50.6 kg/hl

• Particle SizeAverage = 1,282 micronsRange 612 – 2,125 microns

Koch• Bulk Density

Average = 48.4 kg/hlRange 45.4 – 51.3 kg/hl

• Particle SizeAverage = 588 micronsRange 387 – 810 microns

DDGS Physical Characteristics

Angle of ReposeSimilar to Dehy Alfalfa, corn bran, dry malt

Range 40 - 80°

DDGS Nutrient Characteristics

Knott, Shurson and Goihl• Protein

Average = 26.6Range 24.54 – 28.4

• FatAverage = 10.0Range 9.2 – 11.6

• FiberAverage = 6.9Range 5.8 – 9.1

Koch• Protein

Average = 27.6Range 26.3 – 29.9

• FatAverage = 9.2Range 8.1 – 10.2

• FiberAverage = 10.0Range 5.5 – 16.0

DDGS - HandlingDDGS sets up in rail cars, trucks, containers,

barges, (ocean-going vessels ?)• DDGS will set up more than once

Will set up in silos and bins

Currently no flow agents have been found that completely correct the flow/handling problems associated with DDGS• Some may reduce unloading time

from 10 hrs to 5 hrs

Some reports that “New” generation products improve handling characteristics

Practical issues with DDGS Used in Feed Manufacturing

Product is Inconsistent – Unpredictable• Nutrient content

Protein, Fat, Fiber, Moisture, etc.• Nutrient digestibility

esp. for lysine• Physical Characteristics

Bulk density, Particle size, Angle of Repose• Logistics

Multiple producers, brokers/consolidators, shippers• Handling

Flowability – flat storage is recommendedAvailability• Price

MycotoxinsHigh fiber limits its maximum inclusion level in poultry feed

DDGS and Pellet ProductionDecreased pellet quality• Depends on physical and

nutrient characteristics of DDGS

Fat, fiber, protein, moistureParticle size, density

• Depends on ingredientsSome are complementary

• Depends on pellet mill operation

Conditioning time and tempDie speed – slow downDie specifications

Performance ratio

DDGS and Pellet ProductionKoch• DDGS and Durum wheat midds

Increasing DDGS from 0 – 50%A 35% increase in amperageA 41% increase in kilowattsA 15.5% increase in kwh/mtA 3% decrease in pellet quality measured as Pellet Durability Index (PDI)An 11% decrease in pellet bulk density

Increased energy use• Added $0.11/mt to production costs

Decreased pellet quality• may cause reduced feed efficiencies• Increased transportation costs

DDGS and Pellet Production

Koch• DDGS and barley malt sprouts

Increasing DDGS from 0 – 30%A 40% decrease in amperageA 40% decrease in kilowattsA 47% decrease in kwh/mtA 3% decrease in pellet quality measured as Pellet Durability Index (PDI)A 10% decrease in pellet bulk density

Decreased energy use• saved $0.65/mt in production costs

Decreased pellet quality• may cause reduced feed efficiencies• Increased transportation costs

DDGS and Pellet ProductionKoch• DDGS, Durum wheat midds and dry peas

DDGS at 20%, peas at 20%, midds at 60%Compared to 100% midds

o 40% increase in ampso 42% increase in kwo 13% increase in kwh/mto 0.5% increase in PDI

Compared to 60% midds, 40%DDGSo 21% increase in ampso 18% increase in kwo 7.6% increase in kwh/mto 2% increase in PDI

DDGS and Pellet ProductionKoch• DDGS, Durum wheat midds and dry peas

DDGS at 30%, peas at 20%, midds at 50%Compared to 100% midds

o 43% increase in ampso 46% increase in kwo 15% increase in kwh/mto 0.8% decrease in PDI

Compared to 50% midds, 50%DDGSo 6% increase in ampso 3% increase in kwo 2% increase in PDIo 1% decrease in kwh/mt

DDGS and High Shear Conditioning

Alteration of protein and fiber• Operate at greater temperature, pressure and moisture than

pellet millsLow bulk density materials (DDGS) do not absorb moisture readily in pellet mill conditionerHigh natural protein materials (DDGS) becoming “gummy”when moisture addition exceeds 4% and plasticize at temperatures in excess of 63° C

Things to RememberDDGS is a by-product of fuel ethanol production• Typically corn – but can be from other cereals

Physical characteristics of DDGS are dissimilar• Bulk density, particle size and angle of repose are not

uniformNutrient content of DDGS depends on the grain source• Changes nutrient value

The above alter performance of pellet mills and other feed manufacturing equipment

Amy Batal

Thank YouThank You

Fundamentals of pellet productionFundamentals of pellet productionDie Die –– Roller interactionRoller interaction•• Feed on the die face must be Feed on the die face must be

compressed and extruded compressed and extruded through the die holes during through the die holes during successive rotationssuccessive rotations

Excess moisture (> 17%) in Excess moisture (> 17%) in the feed will cause the roll the feed will cause the roll to slipto slip

Resist compressionResist compressionMaterials high in natural Materials high in natural protein and low bulk protein and low bulk density are difficult to density are difficult to pelletpellet

DDGS become DDGS become ““gummygummy””with the addition of with the addition of moisture > 4%moisture > 4%DDGS do not absorb DDGS do not absorb steam wellsteam well

Fundamentals of pellet productionFundamentals of pellet productionIn order to make In order to make pellets must have all pellets must have all forces balancedforces balanced•• Moisture, fat, fiber and Moisture, fat, fiber and

protein have important protein have important role in pellet role in pellet productionproduction

If slipIf slip--resisting force resisting force greater than roll force greater than roll force material will not material will not compresscompress

Caused by moisture, Caused by moisture, fat, proteinfat, protein

If flow resisting force If flow resisting force greater than roll force greater than roll force material will not extrudematerial will not extrude

Caused by fiber, Caused by fiber, particle sizeparticle size

Fundamentals of pellet productionFundamentals of pellet production

Feed material is Feed material is compressed into the die compressed into the die hole and extruded hole and extruded through the effective through the effective length.length.•• Factors that determine Factors that determine

Pellet QualityPellet QualityPerformance ratio (d/L)Performance ratio (d/L)Compression ratio (D/d)Compression ratio (D/d)